LAUSR

Abstract Basalt fiber reinforced polymer (BFRP) composites are increasingly replacing glass and carbon fibers in the automotive and aerospace industries due to higher strength to weight ratio, excellent thermal, mechanical and structural properties. The need for their massive applications to obtain complex shapes can be accomplished by using advanced machining processes such as laser beam cutting (LBC) against conventional cutting techniques. However, in LBC, the dimensional precise and accurate cutting of composite materials is a challenging task in order to produce a higher-quality cut due to the anisotropic and heterogeneous features of the composite. The aim of the present research is to ascertain optimum levels of cutting parameters able to provide geometrically accurate cut for 1.60 mm thick BFRP composite laminate. The influence of five different process parameters viz. lamp current, pulse frequency, pulse width, air pressure and cutting speed on kerf width, kerf deviation, and kerf taper have been evaluated experimentally. Furthermore, a firefly algorithm (FA) based multi-objective optimization approach has been implemented for the simultaneous optimization of all evaluated kerf quality characteristics. Finally, the predicted optimal solutions have been validated by performing confirmation experiments. An overall improvement of 26.75% has been recorded in kerf quality characteristics with an individual improvement of 27.78%, 29.68% and 22.80% in kerf width, kerf deviation, and kerf taper respectively during the evaluation. Moreover, the kerf ratio has been also evaluated and discussed in this article.